1. 1 Tri-Service Power Exposition July 16, 2003 Marine Corps Systems Command

2. 2 Contents of Presentation  Purpose, Mission & Players in USMC Power  Programs and duties of the Program Manager for Expeditionary Power Systems  Science and Technology Efforts  Lessons Learned  Business Opportunity Initiatives  Points of Contact

3. 3 Target Audiences  Fleet Marine Forces & Reserves  Industry participants  Other Services

4. 4 1947 National Security Act  Provide Fleet Marine Forces with combined arms and supporting air components for service with the United States Fleet in the seizures or defense of advanced naval bases and for the conduct of such land operations as may be essential to the execution of a Naval campaign.  Develop, in coordination with the Army, Navy and Air Force, the doctrine, tactics, techniques, and equipment employed by landing forces in amphibious operations.  Develop in coordination with the Army, Navy and Air Force the doctrine, procedures and equipment for airborne operations.

5. 5 Key Players of Acquisition Office of Naval Research Marine Corps Warfighting Lab Acquisition Marine Corps Systems Command Urgent Need Requirements Marine Corps Combat Development Command Experimentation Science & Tech Fleet Marine Forces Policy HQ-MC Service Life Upgrade & Replacement New Doctrine Advocate

6. 6 USMC Acquisition Chief of Naval Research Office of Naval Research Chief of Naval Research Office of Naval Research PM Ground Transportation PM Engineer Systems PM Expeditionary Power Systems Program Managers Commanding General Marine Corps Combat Development Command Commanding General Marine Corps Combat Development Command Commanding Officer Marine Corps Operational Test & Evaluation Activity Commanding Officer Marine Corps Operational Test & Evaluation Activity Combat Equipment & Support Systems Combat Equipment & Support Systems Product Groups MAGTF C4I Battlespace Management & Air Defense Battlespace Management & Air Defense Information Systems Infantry Weapons Systems Infantry Weapons Systems Ground Transportation & Engineer Systems Ground Transportation & Engineer Systems Armor & Fire Support Systems Armor & Fire Support Systems Commandant of the Marine Corps Commandant of the Marine Corps Assistant Secretary Of the Navy Research, Development & Acquisition Assistant Secretary Of the Navy Research, Development & Acquisition Commanding General Marine Corps Systems Command Commanding General Marine Corps Systems Command

7. 7 USMC Program Managers Program Management TeamPM Code Combat Support Information Systems PMM 101 Navy-Marine Corps Intranet / Information Technology PMM 102 Operation CentersPMM 111 Radar SystemsPMM 112 Air Defense Weapon SystemsPMM 113 Ground Command & Control SystemsPMM 121 Communications SystemsPMM 122 Intelligence SystemsPMM 123 Recon & Amphibious RaidsPMM 131 Infantry WeaponsPMM 132 Anti-Armor Systems PMM 133 Fire Support SystemsPMM 141 Tank SystemsPMM 142 Assault Amphibious Vehicle SystemsPMM 143 High Mobility Artillery Rocket System - HIMARSPMM 144 Ground TransportationPMM 151 Engineer SystemsPMM 152 Expeditionary Power SystemsPMM 153 Test, Measurement, & Diagnostic EquipmentPMM 161 Infantry Combat EquipmentPMM 162 Nuclear, Biological & Chemical Defense SystemsPMM 163 Information Systems PG 10 Battle Management & Air Defense - PG 11 MAGTF C4I Systems PG 12 Infantry Weapons Systems - PG 13 Armor and Fire Support - PG 14 Ground Transportation & Engineer Systems - PG 15 Combat Equipment & Support Systems - PG 16

8. 8 PM Advanced Power Team Mobile Power Team Operations & Support Team Mission: “Provide for the acquisition and lifecycle management of assigned programs, explore alternative power source technology”. Power Distribution Power Conditioning Power Generation Energy Storage Standards of Practice Policy Power Consumption Mission & Roles

9. 9 Family of Power Equipment Roll up for 15 different power items Generator sets from 3kW to 100kW Continuous buy effort for TQGs Power Distribution sets, Field wiring, load banks No longer support / train for Mil-Std Generators Discrete Programs Floodlight Sets Non-Standard Generators New power initiatives Mobile Power Team

10. 10 Mobile Electric Power Generation Distribution 10 kW TQG 30 kW TQG 100 kW TQG 60 kW TQG 15, 30, & 100 kW PDS 2 kW MTG (evaluation) 3 kW TQG 5 kW PDS (war effort) Urgent Need for War 15 kW Commercial 21 kW UOC

11. 11 Supported Generators 3 kW, 60 HzMEP Model 831A 10 kW, 60 HzMEP Model 803A 10 kW, 400 HzMEP Model 813A 30 kW, 60 HzMEP Model 805A/B 30 kW, 400 HzMEP Model 815A/B 60 kW, 60 HzMEP Model 806A/B 60 kW, 400 HzMEP Model 816A/B 100 kW, 60 HzMEP Model 007

12. 12 Pending Generators 2 kW, 60 HzMEP Model 531A 2 kW, 28 VDCMEP Model 501A 5 kW, 60 HzMEP Model 802A 15 kW, 60 HzMEP Model 804A 100 kW, 60 HzMEP Model 807A

13. 13 Fielding Model: MEP- 807A Qty: >200 (Subject to Review) Start: 2006/2007 Users: MTACS, MWSG & ESB Fielding Model: MEP- 807A Qty: >200 (Subject to Review) Start: 2006/2007 Users: MTACS, MWSG & ESB Technical Performance The 100 kW TQG is being acquired to satisfy a requirement to replace the current 100 kW Military Standard Generators. This acquisition will produce generators that are comparable to other tactical quiet generators in the DOD family of generators. It will weigh less, be multi-fuel capable, provide reduced audible and infrared signatures, provide improved reliability, and reduce O&M costs. The USMC will procure the unit in a skid-mounted configuration. Technical Performance The 100 kW TQG is being acquired to satisfy a requirement to replace the current 100 kW Military Standard Generators. This acquisition will produce generators that are comparable to other tactical quiet generators in the DOD family of generators. It will weigh less, be multi-fuel capable, provide reduced audible and infrared signatures, provide improved reliability, and reduce O&M costs. The USMC will procure the unit in a skid-mounted configuration. Vendor Integration:Fermont Engine:Caterpillar EPA Certified Vendor Integration:Fermont Engine:Caterpillar EPA Certified 100 kW Tactical Quiet Generator

14. 14 MEP 531 Generator (2 kW)  10 month loan to MEU Service Support Group 24  Deployed with Landing Force 5th/6th Fleet  Used in Kosovo, Djibouti, Kenya, U.A.E, Iraq  Noted benefits and likes:  2-man portable  Easy to operate  Pull started or slave started (like not having batteries to go dead)  Anti-wetstacking device  Electric refueler (refuel itself from a 5-gallon can)  Desires/Dislikes:  Needs an improved muffler system (too noisy)  Would like a protective case for embarkation purposes  To store generator and accommodate anticipated SL-3 / SL-4 items  “Give it fuel and it just keeps on running”

15. 15 Technical/Performance Self-contained system Diesel / JP-8 power plant At least eight hours of continuous operation Light tower Extendable to a height of 30 feet, 360° swivel >300,000 lumens Four remote-able tripod mounted lights > 2,000 lumens each Weigh less than 2,000 pounds External helo transportable Skid-mounted (wheeled units being reassessed) Trailer mounted to M116A3 and M353 trailers Quantity of Buy: 652 (excluding test units) Technical/Performance Self-contained system Diesel / JP-8 power plant At least eight hours of continuous operation Light tower Extendable to a height of 30 feet, 360° swivel >300,000 lumens Four remote-able tripod mounted lights > 2,000 lumens each Weigh less than 2,000 pounds External helo transportable Skid-mounted (wheeled units being reassessed) Trailer mounted to M116A3 and M353 trailers Quantity of Buy: 652 (excluding test units) Floodlight Replacement More Discussion Under Business Opportunities More Discussion Under Business Opportunities

16. 16 Non-Standard Generators  DOD Instruction 4130 addresses non-standard generators  Joint Operating Procedure & Marine Corps Order institutes practice for ALL USMC activities  Request for Deviation must be prepared and submitted to PM- MEP for waiver  Program Manager – Expeditionary Power Systems is USMC Central Control Point (prior to going to PM MEP)  HQ, MCCDC, and MCSC fully support the policy  Request for Deviation should be started prior to development and acquisition  Acquisition Reform does not alleviate this responsibility

17. 17 Mobile Electric Power Study  Issues: Are we buying right type / right quantity of generators What are our future power needs Address those issues we can can have impact upon  Approach Identify Programs across Future Years Defense Plan Task Completed Tabulate and synthesize data / search from trends and issues Stationary / On-the-move power Steady state / Peak power Precise / Utility power 50/60 Hz, 60 Hz, 400 Hz Address power on-hand at FMF / Reserves

18. 18 Marine Expeditionary Unit Power inventory Kilowatts Percentage of Discrete Power Users 17% with 3 kW TQG 62% with 10 kW TQG 94% at with 30 kW TQG

19. 19 Notional Future Power Mix

20. 20 Advanced Medium Sized Mobile Power Sources (AMMPS)  Third generation of military tactical generators  PM-MEP is lead / USMC will be portion of the buy  Will replace ALPHA & BRAVO series TQGs  Addresses 5kW to 60 kW  3 kW TQG will stay in production until 2010  USMC planned fielding for AMMPS to start in 2010

21. 21 Advanced Medium Sized Mobile Power Sources (AMMPS)  Diesel / JP-8 power plant  Technology assessments looked at:  Fuel Cells, turbines, solar, thermo-photovoltaic  Will be electronically controlled, reciprocating engine  Improvements over current TQGs:  15 – 50 % Smaller  15 – 50 % Lighter (fleet and individually)  15 – 50 % More Fuel Efficient  5 – 10 dBA Quieter  20 – 50 % More Reliable  EPA Compliant  Skid & Trailer mounted (Army / USMC differ)  Army will field with a 2-Level Maintenance  USMC will have to assess / adjust if need-be

22. 22 Advanced Power Team  Advanced Power Systems for Communication Equipment (APSCE)  Power Adaptors  Solar  Fuel Cells  Tactical Power supplies  Batteries  Battery Management & Sustainment Systems  USMC Technical POC  Safety certification clearing-house  HAWKER Absorbed Glass Mat  Science and Technology Efforts  Hybrid Electric Vehicles  Under-hood power  Fuel Cell demonstration

23. 23 Suite of devices used to: Power C4I equipment Realize cost avoidance Reduce logistics burden Reduce battery use Commercial off-the-shelf items Suite of devices used to: Power C4I equipment Realize cost avoidance Reduce logistics burden Reduce battery use Commercial off-the-shelf items ALTERNATIVE POWER SOURCES FOR COMMUNICATIONS EQUIPMENT (APSCE) First Technology Increment: SINCGARS Power Adapters Objective: ~4700 end items Fielding: FY03 - FY05 Follow-On Technologies: Radio Power Adaptors Power Converters Battery Management Systems Solar power chargers & adaptors Fuel Cells On-Board Vehicle Power Systems First Technology Increment: SINCGARS Power Adapters Objective: ~4700 end items Fielding: FY03 - FY05 Follow-On Technologies: Radio Power Adaptors Power Converters Battery Management Systems Solar power chargers & adaptors Fuel Cells On-Board Vehicle Power Systems Testing: Mil-Std-810 and Mil-PRF-28800 evaluation for all acquisitions Testing: Mil-Std-810 and Mil-PRF-28800 evaluation for all acquisitions

24. 24 FY02FY06FY07FY05FY03FY04 Solar Power Fuel Cells Power Converters Radio Power Adaptors Single SINCGARS Power Adaptor Multi-SINCGARS Power Adaptor ALTERNATIVE POWER SOURCES FOR COMMUNICATIONS EQUIPMENT (APSCE)

25. 25 SINCGARS Power Adapters  USMC Name: Multi-SINCGARS Power Adapter (MSPA)  Vendor Name: Advanced SINCGARS Alternative Power Supply  Nicknames: ASAPS-6 / MSPA  Energizes up to 6 SINCGARS radios  Input: 110 VAC or 12 VDC  UPS capable if both power sources are connected  Each ASAP-6 receives transport case  ULSS 003702, 15 December 2002  TAMCN H7715  NSN 6130-01-458-4041  USMC Name: Multi-SINCGARS Power Adapter (MSPA)  Vendor Name: Advanced SINCGARS Alternative Power Supply  Nicknames: ASAPS-6 / MSPA  Energizes up to 6 SINCGARS radios  Input: 110 VAC or 12 VDC  UPS capable if both power sources are connected  Each ASAP-6 receives transport case  ULSS 003702, 15 December 2002  TAMCN H7715  NSN 6130-01-458-4041 REMINDER: Direct Vendor Delivery, Acknowledgement of Receipt Required REMINDER: Direct Vendor Delivery, Acknowledgement of Receipt Required

26. 26  USMC Name: Multi-Radio Power Adapter  Vendor Name: Advanced SINCGARS Alternative Power Supply - Suitcase  Nicknames: ASAPS-SC / MRPA  Energizes a up to 6 SINCGARS  UPS capable if both power sources are connected  Input: 110 VAC or 12 VDC  DRAFT ULSS 000503-15  TAMCN H7705  NSN 6130-01-473-0349  USMC Name: Multi-Radio Power Adapter  Vendor Name: Advanced SINCGARS Alternative Power Supply - Suitcase  Nicknames: ASAPS-SC / MRPA  Energizes a up to 6 SINCGARS  UPS capable if both power sources are connected  Input: 110 VAC or 12 VDC  DRAFT ULSS 000503-15  TAMCN H7705  NSN 6130-01-473-0349 SINCGARS Power Adapters REMINDER: Direct Vendor Delivery, Acknowledgement of Receipt Required REMINDER: Direct Vendor Delivery, Acknowledgement of Receipt Required

27. 27  USMC Name: SINCGARS Single Power Adapter (SSPA)  Vendor Name: PAC-216/U  Energize a Single 12 volt SINCGARS  Has an Uninterruptible Power Supply  Internal sealed lead acid rechargeable battery  Internal charging system included  Input: 110 VAC  DRAFT ULSS 003202-15  TAMCN H7710  NSN 6130-01-465-2867  USMC Name: SINCGARS Single Power Adapter (SSPA)  Vendor Name: PAC-216/U  Energize a Single 12 volt SINCGARS  Has an Uninterruptible Power Supply  Internal sealed lead acid rechargeable battery  Internal charging system included  Input: 110 VAC  DRAFT ULSS 003202-15  TAMCN H7710  NSN 6130-01-465-2867 SINCGARS Power Adapters REMINDER: Direct Vendor Delivery, Acknowledgement of Receipt Required REMINDER: Direct Vendor Delivery, Acknowledgement of Receipt Required

28. 28 USMC Fuel Cell Efforts  Requirement under APSCE  Alternative to Batteries  Past Experimentation  On-Going / Future Efforts  Cooperative Efforts Detailed Discussion Under Fuel Cell Session Detailed Discussion Under Fuel Cell Session

29. 29 Battery Efforts  Battery Management and Sustainment Program  Battery Chargers  Rechargeable batteries  Navy Lithium Battery Safety Program  Analyses  MCCDC Battery Study  HQ Battery Conservation Plan  Evaluations  BA-8180 evaluation  HAWKER ArmSafe +  Summary

30. 30 Battery Chargers PP-8444 “Universal Portable Battery Charger”  Can use AC or vehicle DC power  Currently fielded PP 8333/U “Battery Charger - Analyzer“  AC power only  Can charge numerous types PP 8481/U Vehicle "Charger on the move"  Mounts in vehicle, or used on bench-top  Runs off AC or DC power  Will be fielded by MARCORSYSCOM when $$ available PP 8498/U "Soldier Portable Charger"  AC and DC power (only shipped with AC power cable)  Comes with one adaptor to charge two BB-390s/2590s  Can plug in up to 8 batteries, charges only 2 at a time  Will be fielded by MARCORSYSCOM when $$ available

31. 31 Rechargeable Batteries  BB-390 Nickel Metal Hydride battery is still supported by the Army  BB-490 Lead Acid battery is NO longer supported by the Army  BB-590 Nickel Cadmium battery is NO longer supported by the Army  BB-690 Lead Acid battery is NO longer supported by the Army  BB-2590 Lithium Ion, available soon, is Not Approved for USMC use  A7700 charger (PP-8333) - Not yet programmed for the BB-2590

32. 32 BA-5390 LiMn0 2 Battery  REF: MCSC 101842Z MAR 03  BA-5390 APPROVED FOR MARINE CORPS USE WITH SINCGARS ONLY  Developed as an alternative to the BA-5590 lithium sulfur dioxide battery.  Safety certification has been completed for use in SINCGARS radios.  But only BA-5390 Safety Considerations  Has a 16.5 VDC maximum voltage (greater than the BA-5590)  Higher voltage has caused damage to some equipment.  When abused, the BA-5390 battery can ignite into a fire.  Energy capacity is severely degraded if exposed to high temperatures.  Above 190 degrees F, thermal switch will trip - rendering the battery useless.  Equipment covered by approval: AN/PRC-119A AN/PRC-119C AN/PRC-119D AN/PRC-119FAN/VRC-97A(88A) AN/VRC-87C (88A) AN/VRC-89A (91A) AN/VRC-90A AN/VRC-90C AN/VRC-92ART-1523(B) RT-1523 (C) RCU C-11561 (C)

33. 33 Lithium Based Batteries SAFETY REMINDER SAFETY ALERT FOR 2590 LITHIUM RECHARGEABLE BATTERIES  MARCORSYSCOM MSG 281516 Sept 01  MARCORSYSCOM MSG 240921Z Apr 02  ALL LITHIUM BATTERIES or products containing lithium batteries as backup power sources must be reviewed, tested and approved as directed under the Navy Lithium Battery Safety Program.  BB-2590 batteries or power sources using BB-2590 batteries as an UPS device have not been approved for USMC applications.

34. 34 MCCDC Battery Study Estimated completion: Fall 2003 Task I Identify End Items requiring batteries Task II Identify End Item quantities Task III Recommend Battery types & amounts Task IV Estimate Consumption Rates Task V Develop Battery Prediction Tool  Hot  Cold  Temperate  Storage

35. 35 Recommendation: Four rechargeable batteries for each battery in equipment powered: One in the equipment, one for back up, one in transit to the equipment, and one on the charger. Some units have successfully used a three to one ratio. Battery Conservation Plan Concept of Operations (Pending Marine Corps Order to be issued from HQ) 1.Reserve the use of primary batteries in equipment applications to those missions where they are the only practical option. 2.If Alternating Current (AC) power is available, either in garrison via facility power or in the field via generators, use AC energized power adapters, power supplies, or AC powered power sources/converters to power the equipment. 3.If Direct Current (DC) power is available, use DC energized power sources/converters to power the equipment. 4.If neither AC nor DC power is available, and the mission can be accomplished using secondary batteries (i.e., rechargeable batteries), then use rechargeable batteries. Depending on mission duration, recharging operations can be conducted during or after the mission.

36. 36 BA-8180 Zinc-Air Battery  Cooperative Effort with US Army Communications and Electronics Command (CECOM) and Marine Corps Warfighting Laboratory  2d Marines, II MEF utilized ZINC-AIR power packs during CAX 9/10  Summer at 29 Palms California  Worked on all tactical radios except EPLRS  Ideal for retransmission sites  Powered a PSC-5 net for four straight days  One battery lasted 8 days on an Infantry Battalion Regimental TAC1 VHF net  Longevity: consistently lasted 4-6 times the planned runtime of a BA-5590  Weight Savings: Reduced battery carried load by ~ 40%  Transmission Ratio: Volume of transmissions did not affect longevity of the battery  Connections: Marines experimented with adaptors and found the battery easy to connect and use

37. 37 HAWKER ArmSafe+ Batteries  Funding received in 2003 to procure HAWKER ARMASAFE PLUS (HASP)  Procured & distributing 11,750 HASP batteries  Provides a buffer to soften cost difference between existing 6TMF & HASP  Being fielded to Tactical Wheeled Vehicle fleet community  Any future funding will address other equipment / fleets  Instructions issued via DMS:  MCSC 132130Z JAN 03,  MCSC 061812Z MAR 03,  MCSC 041437Z MAR 03,  MCSC 011430Z MAY 03  BATTERY SAFETY ALERT & UPDATE issued for installation instructions  Program is conducting evaluation of performance between the 6T & HASP  Evaluation will take place over a 36-month period

38. 38 Battery Summary  HAWKER ARMASAFE PLUS batteries and 6T series batteries cannot be combined in the same application / on the same vehicle  BA-5390 is only approved for Marine Corps use with SINCGARs  The BB-2590 Lithium Ion is not yet approved for USMC use  PP-8333 battery charger not programmed for the BB-2590 at this time  ALL lithium batteries, to include backup power sources, must be reviewed, tested, and approved under the Navy Lithium Battery Safety Program.  You need to buy special adaptors (which are reusable) when you purchase BA-8180 batteries Having an NSN does not constitute being safety tested or being approved for use

39. 39 Science and Technology Efforts

40. 40 Science & Technology Efforts  Lightweight Generator Efforts  Lighter weight compared to current MEP-831 TQG  New concepts (to include fuel cells)  Incremental improvements  Reduced noise  Hybrid system  Bigger than batteries  Smaller than TQG  Alternative power sources  On-Board Power Generation  Solar Power Adaptors  Hybrid Electric Vehicles (Details at next session)

41. 41 Alternative Energy Conversion 50 - 500 Watts ALTERNATIVES ADDRESSED:  Power derived from Human Activity  Internal Combustion Engines  External Combustion Engines  Thermoelectrics  Fuel Cells  Thermo-Photo-Voltaics (TPV) FINDINGS  Fuel cells are most attractive (but JP-8 issue)  TPVs being addressed under SBIR Program  Stirling engine/linear alternator has tactical power niche up to the 100-W level  Human power and thermo-electrics not viable  High-speed miniature machinery has potential Miniature Turbo Generators Power from Human Movement

42. 42 Thermophotovoltaic Fuel Cells: 50- to 500-W Range Thermoelectric Generators Internal Combustion Micro Diesel Alternative Comparison (3-kW size)

43. 43 $$ Alternative System Weight Comparison (3-kW TQG) (48.3)166.6164.813761.60 Weight Advantage vs. Current TQG 374.7159.8161.6189.4264.8326.4Total Weight 15.620 25 Fuel (8-hr Supply) 169.1111.5116.6129.4169.8222.8Balance of Plant 16013.320254648.8Engine 30155 2429.8Battery Stirling Engine Fuel Cell (2kg/kW) High RPM Turbine High RPM Diesel Light Wt. TQG Current TQG Generator Component $$$ $$$$$$$

44. 44 Turbine Mini-Power System Technical Objectives Develop a compact, lightweight 3 kW mini- Brayton power source. Demonstrate system size, weight, and logistic fuel consumption goals in laboratory and field prototype tests. Develop supporting component technologies that allow scaling to greater power levels. Technical Objectives Develop a compact, lightweight 3 kW mini- Brayton power source. Demonstrate system size, weight, and logistic fuel consumption goals in laboratory and field prototype tests. Develop supporting component technologies that allow scaling to greater power levels. Program Background Performer: Penn State Univ Principal:Dr. Daniel Kiely Sponsor: Office of Naval Research Start Date:2003 Complete:2005 Deliver: Working prototype Program Background Performer: Penn State Univ Principal:Dr. Daniel Kiely Sponsor: Office of Naval Research Start Date:2003 Complete:2005 Deliver: Working prototype

45. 45 2 kW Ultra Lightweight Generator  Electrical Output Power: 2 kW  Voltage: 28 VDC  Size: 14”(L) x 11”(W) x 16”(H)  Weight: 47 lbs  Engine Characteristics  4-stroke, Single cylinder  Air-Cooled  Naturally-aspirated  Compression-ignition  Shaft Power 2.8 kW  Fuel:  Diesel  JP-5, JP-8, kerosene (reduced output)  6 hr on-board fuel  Interfaces:  Manual recoil starter  Voltmeter, ammeter, hour meter  Circuit Load Protection  Electrical Output Power: 2 kW  Voltage: 28 VDC  Size: 14”(L) x 11”(W) x 16”(H)  Weight: 47 lbs  Engine Characteristics  4-stroke, Single cylinder  Air-Cooled  Naturally-aspirated  Compression-ignition  Shaft Power 2.8 kW  Fuel:  Diesel  JP-5, JP-8, kerosene (reduced output)  6 hr on-board fuel  Interfaces:  Manual recoil starter  Voltmeter, ammeter, hour meter  Circuit Load Protection Sponsor: PM Intel Systems Vendor: Mainstream Engineering Method: Small Business Innovative Research (SBIR) Program Sponsor: PM Intel Systems Vendor: Mainstream Engineering Method: Small Business Innovative Research (SBIR) Program

46. 46 Advanced Materials to Reduce System Weight and Signature Program Background Performer: Pacific Northwest Nat’l Lab Principal:Mr. Chip Larson Sponsor: Office of Naval Research Start Date:2002 Completion:2003 Deliverable:Technical Report Program Background Performer: Pacific Northwest Nat’l Lab Principal:Mr. Chip Larson Sponsor: Office of Naval Research Start Date:2002 Completion:2003 Deliverable:Technical Report Weight reduction of 36% realizable with composite materials Volume reduction of 31% possible with redesign on 3 kW TQG enclosure 65 dBA maximum acoustic emission expected with redesigned exhaust IR signature reducible to <65°C with redesign & thermo-acoustic material Findings provided to PM-MEP for AMMPS – no USMC demonstration planned Weight reduction of 36% realizable with composite materials Volume reduction of 31% possible with redesign on 3 kW TQG enclosure 65 dBA maximum acoustic emission expected with redesigned exhaust IR signature reducible to <65°C with redesign & thermo-acoustic material Findings provided to PM-MEP for AMMPS – no USMC demonstration planned

47. 47 Hybrid Zn-Air / UltraCapacitor Li/SO 2 BA-5590 Zn/Air Capacitor Zn/Air 1010 100 1,000 10,000 1 0.1 1 10 100 Hybrid Battery Capacitor POWER ENERGY Program Background Performer: NSWC-Carderock Principal:Dr. Patricia Smith Sponsor: Office of Naval Research Start Date:2003 Completion:2005 Deliverable:Evaluation models Program Background Performer: NSWC-Carderock Principal:Dr. Patricia Smith Sponsor: Office of Naval Research Start Date:2003 Completion:2005 Deliverable:Evaluation models Technical Objectives Develop hybrid power supply Use modeling to guide decisions Employ zinc/air for high energy Employ ultra-capacitors for high power Modular System - Zn/Air switches out 30% Reduction in weight over BA-5590 2X Power capability Technical Objectives Develop hybrid power supply Use modeling to guide decisions Employ zinc/air for high energy Employ ultra-capacitors for high power Modular System - Zn/Air switches out 30% Reduction in weight over BA-5590 2X Power capability

48. 48 Solar Power Adaptor  Overarching Requirement  APSCE Program  Statement Of Need – staffing  Must provide sufficient power for:  Radios  Computers  Charge batteries  Experimentation in 2004  Planned introduction 2006  Quantities > 1,000  Will undergo Operational Test & Evaluation  Overarching Requirement  APSCE Program  Statement Of Need – staffing  Must provide sufficient power for:  Radios  Computers  Charge batteries  Experimentation in 2004  Planned introduction 2006  Quantities > 1,000  Will undergo Operational Test & Evaluation More Discussion Under Solar Power Session More Discussion Under Solar Power Session

49. 49 Program Background Performer: MTS / Army / USMC Principal:Mr. Jim Gough, MTS Sponsor: Office of Naval Research Start Date:2002 Completion:2004 Deliverable:COTS hardware Program Background Performer: MTS / Army / USMC Principal:Mr. Jim Gough, MTS Sponsor: Office of Naval Research Start Date:2002 Completion:2004 Deliverable:COTS hardware Current COTS: 5-8 kW, belt driven USMC - Army demonstration hosted in January 2003 at Quantico USMC base Pending requirement approval and funding - planned procurement in 2006 System selection & test in 2004 / 2005 Current COTS: 5-8 kW, belt driven USMC - Army demonstration hosted in January 2003 at Quantico USMC base Pending requirement approval and funding - planned procurement in 2006 System selection & test in 2004 / 2005 On-Board Vehicle Power Small Power

50. 50  Current vehicle generators provide single digit kilowatts  Current COTS: 5-8 kW, belt driven  Additional power will be needed for stationary systems that need to be expeditionary  Future vehicle systems need double digit capability Need PowerTime Radars30-60 kW 2007 CAC2S13 kW2006 UOC 21 kW2005 (refresh) NBC 12-20 kWsoon  Current vehicle generators provide single digit kilowatts  Current COTS: 5-8 kW, belt driven  Additional power will be needed for stationary systems that need to be expeditionary  Future vehicle systems need double digit capability Need PowerTime Radars30-60 kW 2007 CAC2S13 kW2006 UOC 21 kW2005 (refresh) NBC 12-20 kWsoon  3 year effort – 2004 – 2006  Competitive solicitation  3-prong approach (20, 30, 60 kW)  HMMWV & MTVR platforms  Deliver TRL 07 by 2006  Platforms to be delivered for mission equipment integration  3 year effort – 2004 – 2006  Competitive solicitation  3-prong approach (20, 30, 60 kW)  HMMWV & MTVR platforms  Deliver TRL 07 by 2006  Platforms to be delivered for mission equipment integration On-Board Vehicle Power Large Power

51. 51 Hybrid Electric Drive System Fuel economy - 17 mpg 8 hours Silent watch 25 miles Silent movement Component distribution In Hub Drive Motors Efficient space utilization Improved mobility Redundancy for fail-safe Folding Suspension Minimize volume for helo Wide wheelbase for stability Battery Energy Storage On-board power needs Off-board power needs Hybrid Electric Drive System Fuel economy - 17 mpg 8 hours Silent watch 25 miles Silent movement Component distribution In Hub Drive Motors Efficient space utilization Improved mobility Redundancy for fail-safe Folding Suspension Minimize volume for helo Wide wheelbase for stability Battery Energy Storage On-board power needs Off-board power needs Program Accomplishments uFY 97-98: Competitive Designs uFY98-02: Build / Test 4 vehicles uParticipate in Warfighting experiments Program Accomplishments uFY 97-98: Competitive Designs uFY98-02: Build / Test 4 vehicles uParticipate in Warfighting experiments ONR / DARPA Hybrid Electric RST-V Detailed Discussion – Next Session Program Accomplishments uFY 97-98: Competitive Designs uFY98-02: Build / Test 4 vehicles uParticipate in Warfighting experiments Program Accomplishments uFY 97-98: Competitive Designs uFY98-02: Build / Test 4 vehicles uParticipate in Warfighting experiments

52. 52 Lessons Learned

53. 53  Big Power (Tactical Quiet Generators / Mobile Power Distribution)  Worked as advertised, but users continue to want more power/generators  Sent tactical systems forward – leased/bought commercial units for rear  Power distribution units stretched thin – long lead items  Mobile Power (vehicle on-board APUs, inverters, battery chargers)  Requests for more systems  Large opportunity for improvement and payoff  Batteries (one-time use batteries, rechargeable batteries, alternative power sources)  Will never be "one size fits all"  Have to provide options Power Systems Lessons

54. 54 Commercial Generator Buy  35 commercial electrical generators  3 Bids solicited and received  Contract Award: Magnum Products LLC  CONUS delivery in 7 days  6 months consumable parts block  One - time buy / Non-Std waiver granted  35 commercial electrical generators  3 Bids solicited and received  Contract Award: Magnum Products LLC  CONUS delivery in 7 days  6 months consumable parts block  One - time buy / Non-Std waiver granted  Urgent Requirement received from Iraq  Existing TQGs unavailable to meet need  Diesel / JP-8 fuel compatible  Provides at least 15 kilowatts electrical power  Less than 2000 pounds wet weight  Delivery AS SOON AS POSSIBLE  Urgent Requirement received from Iraq  Existing TQGs unavailable to meet need  Diesel / JP-8 fuel compatible  Provides at least 15 kilowatts electrical power  Less than 2000 pounds wet weight  Delivery AS SOON AS POSSIBLE

55. 55 MEP Distribution (MEPDIS)  USMC currently employ MEPDIS  Similar to Army PDICE  Long lead-time, expensive  Planning now for future MEPDIS  Developed, tested and fielded 5 kW Power Distribution System (PDS) for Forward Resuscitative Surgical Suite (FRSS) in preparation for Iraqi Liberation  Commercial components, NEMA 4 capability  30% of the cost of MEPDIS / PDICE  E-MEPDIS developed under SBIR a  Deployed to Iraq  Lessons not received back yet

56. 56 Business Opportunity Initiatives

57. 57 Floodlight Replacement System Acquisition Strategy  Fully commercial or modified commercial item  FedBizOpps announcement & solicitation  Submission of proposal with Bid Sample  Selection based on proposal & bid sample findings  Production testing (single vendor, 2-5 units)  Full Quantity Buy / Production / Fielding  Warranty & World Wide Support will be required Acquisition Strategy  Fully commercial or modified commercial item  FedBizOpps announcement & solicitation  Submission of proposal with Bid Sample  Selection based on proposal & bid sample findings  Production testing (single vendor, 2-5 units)  Full Quantity Buy / Production / Fielding  Warranty & World Wide Support will be required Solicitation & Procurement will be Rapid Turn- Around  2002 Program Initiation (money deferred)  Prototypes being tested in FY03 and FY04  Acquisition Policy / Adequate Competition support:  Federal purchase schedule preference  COTS / NDI preference  2005 or 2006 program restart anticipated  2002 Program Initiation (money deferred)  Prototypes being tested in FY03 and FY04  Acquisition Policy / Adequate Competition support:  Federal purchase schedule preference  COTS / NDI preference  2005 or 2006 program restart anticipated

58. 58 ADVANCED POWER SYSTEMS FOR COMMUNICATIONS EQUIPMENT FY02FY06FY07FY05FY03FY04 Solar Power Fuel Cells Power Converters Radio Power Adaptors Single SINCGARS Power Adaptor Multi-SINCGARS Power Adaptor

59. 59 On-Board Vehicle Power Generation Program Plan – Large Power Systems – ONR Lead  Competitive solicitation – 2004  Design / Fabricate / Test – 2005-2007  3-prong approach (20, 30, 60 kW)  HMMWV & MTVR platforms  Deliver Technology Readiness Level TRL 07  Follow-on equipment integration on platforms Program Plan – Large Power Systems – ONR Lead  Competitive solicitation – 2004  Design / Fabricate / Test – 2005-2007  3-prong approach (20, 30, 60 kW)  HMMWV & MTVR platforms  Deliver Technology Readiness Level TRL 07  Follow-on equipment integration on platforms

60. 60 Points of Contact  MARCORSYSCOMMiscellaneousMr. Michael Gallaghergallagherma@mcsc.usmc.mil  MARCORSYSCOM Advanced PowerMrs. Joanne Martin martinjm @ mcsc.usmc.mil  MARCORSYSCOM Mobile PowerCWO5 Richard Triviso trivisorr@mcsc.usmc.mil  MARCORSYSCOM Science & TechMr. Scott Story storyws@mcsc.usmc.mil  MARCORSYSCOMHAWKER AGMMGySgt Henry Favorfavorhc@mcsc.usmc.mil  ONR (6.1)Science & TechMr. Cliff Anderson anderscw@onr.navy.mil  ONR (6.2)Science & TechMaj Craig Penrose Craig_Penrose@onr.navy.mil  ONR (6.3)Science & TechMr. Mike Byerly Michael_Byerly@onr.navy.mil  CarderockZn-Air HybridDr. Patricia Smith SmithPH@nswccd.navy.mil  MTSOn-Board PowerMr. Jim Gough goughj@mtstech.com  PNNLAdvanced TechMr. Chip Larson Chip.Larson@pnl.gov

61. 61 Questions & Answers